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Trianco Contractor HE Wall Mounted Internal Oil Boilers ... - BHL.co.uk

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WM70 <strong>HE</strong> INTERNALOIL-FIRED CENTRAL <strong>HE</strong>ATING BOILERFOR BALANCED FLUEUSER, INSTALLATION,COMMISSIONING & SERVICINGINSTRUCTIONSPlease read these instructions carefully before installing,<strong>co</strong>mmissioning and using this appliance.To be retained by the householder1


<strong>HE</strong>ALTH AND SAFETY INFORMATIONINFORMATION FOR T<strong>HE</strong> INSTALLER AND SERVICE ENGINEERSUnder the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is arequirement to provide information on substances hazardous to health (COSHH Regulations 1998).<strong>Trian<strong>co</strong></strong> takes every reasonable care to ensure that these products are designed and <strong>co</strong>nstructedto meet these general safety requirements, provided they are properly installed and used.To fulfil this requirement, products are <strong>co</strong>mprehensively tested and examined before despatch.When working on the appliance, it is the responsibility of the user/engineer to ensure that anynecessary personal protective clothing or equipment is worn appropriate to parts which <strong>co</strong>uld be<strong>co</strong>nsidered hazardous or harmful.This appliance may <strong>co</strong>ntain some of the items below:Insulation and SealsGlass rope, mineral wool, insulation pads, ceramic fibre, glass insulation.May be harmful if inhaled. May be irritating to the skin, eyes, nose and throat. When handling,avoid inhalation and <strong>co</strong>ntact with the eyes. Use disposable gloves, face masks and eye protection.After handling, wash hands and other exposed parts. When disposing, reduce dust with waterspray and ensure all parts are securely wrapped.Glues, Sealants and PaintsGlues, sealants and paints are used in this appliance and present no known hazards when used inthe manner for which they are intended.Kerosene & Gas <strong>Oil</strong> Fuels (Mineral <strong>Oil</strong>s)Avoid as far as is possible any skin <strong>co</strong>ntact with mineral oils or with materials <strong>co</strong>ntaminated withmineral oils. The effects of mineral oils on the skin may vary ac<strong>co</strong>rding to exposure:1) May remove the protective grease normally present on the surface of the skin, rendering it dry,liable to crack and more prone to damage caused by cuts and abrasions.2) May result in skin rashes. Seek immediate medical attention for any rash, wart or soredeveloping on any part of the body, especially the scrotum.Never breathe any mineral oil vapours. Do not fire the burner in the open (i.e. not properly situatedin the boiler) as misfiring may result in unburned oil vapours.When handling mineral oils, a suitable barrier cream <strong>co</strong>ntaining lanolin is highly re<strong>co</strong>mmended,along with a strict routine of personal cleaning.Under no circumstances should mineral oils be taken internally.2


CONTENTS1. USER INSTRUCTIONSIntroductionHow to use the boilerAfter-sales service information2. INTRODUCTION TO INSTALLATIONInstallation notesFlushing and water treatment3. TECHNICAL INFORMATIONBoiler dimensionsPipework <strong>co</strong>nnectionsTechnical data4. INSTALLATIONRegulations / Health & SafetySiting and clearancesSystem designHeating & hot water systemsCondensate Pipework5. OIL SUPPLY<strong>Oil</strong>Storage tankSingle pipe oil supplyTwo pipe oil supply<strong>Oil</strong> de-aerators6. ELECTRICAL SUPPLYWiring diagram7. MOUNTING8. FLUES AND VENTILATIONInstallation notesVentilationBalanced flue kits9. COMMISSIONING10. SERVICINGProcedureBaffle <strong>co</strong>nfiguration11. SPARES LIST12. BURNER FAULT-FINDING444-56777888910101010101112121212-1412-151316161718181819-29303030-31313233-343


1. USER INSTRUCTIONSPlease note, to assist <strong>Trian<strong>co</strong></strong> in improving customer service, itis important that the guarantee/registration card is returned.INTRODUCTIONThe <strong>Contractor</strong> WM70 <strong>HE</strong> has been designed and <strong>co</strong>nstructedto give years of trouble-free service and these instructions areprovided to assist you in obtaining the best performance withthe least trouble and <strong>co</strong>st.The boiler is designed to provide both domestic hot water andcentral heating. It is supplied with an adjustable boilertemperature <strong>co</strong>ntrol thermostat and a manual-reset high-limitthermostat, requiring little attention other than the setting ofany additional system <strong>co</strong>ntrols (such as a room thermostat orprogrammer).TO FIRE T<strong>HE</strong> BOILERBefore firing the boiler, ensure that the system is full of water,that there is a sufficient level of oil in the storage tank, and thatall isolation valves are fully open.Check that the time-switch/programmer is on and that theroom thermostat is calling for heat.Set the boiler thermostat (fig 1) to the desired temperature.Switch on the electrical supply; the burner will fire up and<strong>co</strong>ntinue to run until the boiler reaches the temperature set onthe boiler thermostat.Set the time-switch/programmer to the times and programmerequired. The boiler should now operate automatically, cuttingin and out ac<strong>co</strong>rding to the heat demand.TO STOP T<strong>HE</strong> BOILERThe boiler may be switched off by turning off the boiler <strong>co</strong>ntrolthermostat fully anti-clockwise to the off position, ‘O’.If the boiler is to be off for a long period of time, it isre<strong>co</strong>mmended that the mains supply to the appliance isswitched off, or the time-switch/programmer (if fitted) is set tothe OFF position.BOILER CONTROL T<strong>HE</strong>RMOSTATThe boiler <strong>co</strong>ntrol thermostat allows you to adjust thetemperature of the water leaving the boiler. It is calibratedbetween High and Low, in five intermediate settings,<strong>co</strong>rresponding to a temperature range between 80°C (High)and 55°C (Low). The thermostat is switched off when the knobis turned fully anti-clockwise to the 'OFF' position.Experience will tell you which is the most e<strong>co</strong>nomical setting tosuit your household.HIGH-LIMIT T<strong>HE</strong>RMOSTATThe high-limit thermostat is factory-set and requires noadjustment. Should the boiler thermostat malfunction and thewater temperature rise to 110°C, the limit thermostat will takeover and shut down the appliance.The limit thermostat is located on the front of the <strong>co</strong>ntrol boxand can be reset by pushing in the red button. If the thermostatoperates frequently, <strong>co</strong>nsult your service engineer, as theremay be a fault in the system.Note: the high-limit thermostat can only be reset when thewater temperature has dropped by at least 20°C.BURNER LOCK-OUTIf the burner fails to light for any reason, the boiler will go intolock-out mode, indicated by the illumination of the reset buttonon the burner <strong>co</strong>ntrol box (fig 2). To reset the burner, pressthis button. If the burner returns to lock-out, wait for one minutebefore pressing the button again.If the burner still fails to light, follow the simple fault-findingguide (page 5), before switching off the electrical supply to theboiler and <strong>co</strong>ntacting your service engineer if the failurepersists.Important: do not attempt to reset the burner more thantwice – <strong>co</strong>nstant attempts to do so may cause permanentdamage to <strong>co</strong>mponents within the burner.BOILER LOCK-OUTLIGHT &RESET BUTTONFIG 1FIG 24


SYSTEM CONTROLSROOM T<strong>HE</strong>RMOSTATThe room thermostat should not be positioned near a source ofheat, such as a radiator, or be exposed to direct sunlight, asthis will cause the heating to switch off before the room is up tothe <strong>co</strong>rrect temperature. Always follow the manufacturer’sinstructions for the best siting position of the room thermostat.FROST PROTECTIONIf the boiler is to be fitted externally to the property beingheated, the water in the system may be in danger of freezingand, as such, it is advisable to protect the installation with afrost thermostat, which will bring the heating on when required.Where the system is not protected, the heating should be leftswitched on and the room thermostat left at a low setting (e.g.7°C) to prevent the building temperature falling too low.If the system is shut down for a long period during very <strong>co</strong>ldweather, it is also advisable to <strong>co</strong>mpletely drain the system.However, too frequent draining of the system should beavoided, especially in hard water areas, as this <strong>co</strong>uld lead toscaling of the boiler waterways.See page 7 for flushing and water treatment.SHUTTING DOWN FOR LONG PERIODSIf the boiler is shut down for any length of time, it isadvisable to have it serviced and thoroughly cleaned as soonas possible to minimise <strong>co</strong>rrosion of the heating surfaces.OILThe oil for your boiler is 28 sec. Kerosene class C2 to BS2869.Always ensure that the oil storage tank is topped up regularly;do not wait until the tank is nearly empty before refilling, assludge and water <strong>co</strong>uld be sucked into the oil pipe, affectingthe operation of the burner and potentially reducing the life ofthe pump.After a delivery of oil, it is re<strong>co</strong>mmended that it be allowed tosettle in the tank for about half an hour before restarting theboiler.Sludge and water caused by <strong>co</strong>ndensation should be drawn offat the drain-<strong>co</strong>ck on the oil tank annually.SIMPLE FAULT-FINDINGIf the boiler fails to start for no apparent reason, carry out thefollowing checks before calling your service engineer:1. Check for failure in the electrical supply.2. Check for a blown fuse. If the fuse has blown and thereplacement subsequently blows again, switch off themains electrical supply to the boiler and <strong>co</strong>ntact yourservice engineer.3. Check that there is adequate oil in the tank and that allisolation valves are fully open.4. Check for burner lock-out (see page 4).5. Check for excess water temperature (see high-limitthermostat details, page 4, for further details).Note:SERVICINGIf the boiler has been shut down due to a failure of thepower supply, it may be necessary to reset the timeswitchor programmer to the <strong>co</strong>rrect time, unless thedevice has an in-built power reserve.To ensure the efficient and reliable operation of the boiler it isessential that the burner be <strong>co</strong>mmissioned immediately afterinstallation, and prior to first use. The boiler requires an annualservice thereafter.IMPORTANT NOTES1. Only an OFTEC-trained and registered engineer can carryout <strong>co</strong>mmissioning and service work.2. Electrical safety checks should be carried out by aqualified electrical engineer.3. It is the responsibility of the installer to ensure that theboiler is <strong>co</strong>mmissioned immediately after installation.4. It is a requirement of the guarantee and any extendedwarranty that an annual service is carried out.5. The system water must always be protected by a<strong>co</strong>rrosion inhibitor.5


AFTER-SALES SERVICE INFORMATIONA qualified field service engineer is available to attend abreakdown or manufacturing fault occurring while theappliance is under guarantee.The appliance must be made available for service duringnormal working hours, Monday to Friday.TECHNICAL ASSISTANCEA team of trained technical advisors are available to discussany problem with the appliance which may occur. In manycases, the problem may be solved over the telephone,eliminating the need for a service visit.Please note, upon attendance by a <strong>Trian<strong>co</strong></strong> fieldservice engineer, a charge will be made on-sitewhere:• The field service engineer finds no fault with theappliance• The cause of the appliance is due to lack of oil, or afault in the oil supply• The cause of a breakdown is due to other parts ofthe system not manufactured by <strong>Trian<strong>co</strong></strong>• The cause of the breakdown is due to in<strong>co</strong>rrectlyfitted spare parts, or third-party spares notdesigned for specific use with the appliance• The appliance has not been <strong>co</strong>rrectly installed asre<strong>co</strong>mmended in these instructions, or byunqualified persons• The breakdown occurs outside the guaranteeperiod• The appliance has not been maintained <strong>co</strong>rrectly• The breakdown occurs due to use of the appliancenot sanctioned by these instructions• The breakdown occurs as a direct result ofunauthorised third-party work on the applianceImportant:Invoices for attendance and repair work carried outon this appliance by any third party will not beaccepted unless authorised in advance by the<strong>Trian<strong>co</strong></strong> service centre.HOW TO REPORT A FAULTStep 1:Contact your installer or service engineer, who shouldthoroughly check all recent work before the attendance ofour field service engineer is requested.Step 2:If your appliance has developed an in-guarantee fault,<strong>co</strong>ntact the <strong>Trian<strong>co</strong></strong> service centre for assistance. You willbe provided with the name and <strong>co</strong>ntact details of our localservice agent.If your own installer/service engineer is unavailable, <strong>co</strong>ntactthe <strong>Trian<strong>co</strong></strong> service centre. Please be aware that a chargemay be made for any visit not <strong>co</strong>vered by the applianceguarantee.Before <strong>co</strong>ntacting either the <strong>Trian<strong>co</strong></strong> service centre orthe technical advice line, please have the followinginformation ready:1) Appliance serial number, or your unique customeridentification number (issued upon registration of theappliance with <strong>Trian<strong>co</strong></strong>)2) Description of fault3) Date of installationBoiler Serial No.: __________________________Cust. ID No.:Installation Date: ___/___/_____________________________Corrosion Inhibitor Fitted: YES: ___ NO: ___SERVICE CENTRE AND TECHNICAL SUPPORTTel: 0114 257 2300 Fax: 0114 257 2338Hours of BusinessMonday – Thursday: 8:30 – 16:45Friday: 8:30 – 14:306


INSTALLATION INSTRUCTIONS2. INTRODUCTIONThe <strong>Contractor</strong> WM70 <strong>HE</strong> has been designed to <strong>co</strong>nform toEuropean Directive/Standards BED 92/42 EEC LVD EN 73/23EEC EMC 89/336/EEC.The matched pressure-jet burner is exceptionally quiet inoperation and ensures clean and efficient <strong>co</strong>mbustion, with lowNOx emissions.The boiler is designed for sealed systems up to a workingpressure of 3 bar, with the appropriate sealed system safetyequipment.To ensure that the boiler is operating at maximum efficiency,the central heating return temperature should be 50°C orabove. Maximum performance will be achieved by maintaininga differential of 20°-30°C between the flow and return watertemperatures.This appliance is suitable for sealed, fully pumped systemsonly.Routine servicing can be carried out from the front of the boiler.The boiler is fully automatic in operation and in<strong>co</strong>rporates allnecessary safety <strong>co</strong>ntrols to ensure safe and reliable running.The boiler is supplied with the burner set for 28 sec. KeroseneClass C2 to BS 2869 fuel to meet the Building Regulationrequirements for low-level flue discharge.FLUSHING AND WATER TREATMENTThe performance of the appliance <strong>co</strong>uld be impaired by systemdebris or the effects of <strong>co</strong>rrosion. New systems must bethoroughly flushed to remove metal filings, solder, machiningoils and any other fluxes or greases before <strong>co</strong>nnecting theboiler.When fitting the appliance to an existing system, it is advisableto clean the system by using an appropriate flushing anddescaling agent. Refer to BS 7593 [1992] for guidance.System additives - <strong>co</strong>rrosion inhibitors and all flushingagents/descalers should be suitable for steel boilers and<strong>co</strong>mply with BS 7593 requirements. It is stronglyre<strong>co</strong>mmended that a suitable anti-freeze product is applied tothe system after flushing.Always refer to manufacturers' instructions.Failure to flush and add inhibitors to the system willinvalidate the appliance warranty.The appliance is designed to be fitted to fully-pumpedsystems only. Failure to do so will invalidate the warranty.The boiler must not be run without water in the system.BALANCED FLUE KITSThe boiler is supplied equipped for <strong>co</strong>nnection to a <strong>Trian<strong>co</strong></strong>balanced flue kit (sold separately). These kits allow the boilerto be installed in a wide variety of site <strong>co</strong>nditions, from lowleveldischarge through the wall, to high-level and verticaldischarge (see page 19 onwards for details).The flue kit is available in low-level horizontal, vertical and highlevel horizontal formats.As a balanced flue boiler, the <strong>Contractor</strong> WM70 <strong>HE</strong> is a roomsealedappliance which <strong>co</strong>nforms to the requirements specifiedin OFSA100. All flue types are suitable for installation in agarage.IMPORTANT NOTICE:To <strong>co</strong>mply with regulations in force, the boiler must be installed and <strong>co</strong>mmissioned by an OFTEC-registered engineer. Theinstallation must <strong>co</strong>mply with all requirements of current Building Regulations, Part L.Failure to meet the terms of these requirements may invalidate the guarantee.T<strong>HE</strong> PERSON(S) WHO INSTALLS THIS APPLIANCE, SERVICES OF CARRIES OUT ANY REMEDIAL WORK, i.e. ELECTRICALFAULT-FINDING, MUST HAVE T<strong>HE</strong> SUITABLE ENGINEERING QUALIFICATIONS.7


3. TECHNICAL INFORMATIONALL DIMENSIONS IN mm.FIG 3OUTLINE DIMENSIONSFIG 4PIPEWORK CONNECTIONS8


TECHNICAL DATAInput (net)74,723 BTU/hOutput (net)70,970 BTU/hSEDBUK RatingABurnerSee Burner Details LeafletWeight (empty)91kgWater Content16 litresFlow & Return22mm CompressionMax. Operating Pressure (HTG)3 bar (43.5 psi)Test Pressure4.5 bar (65.3 psi)Starting Current 3.5Running Current 0.77Electrical Supply230/240v – 50Hz 220WFuseFused at 5 ampMaximum Pressure3 barFuelKerosene 28s BS 2869 Class C2Hot Water Thermostat Adjustable between 55°C and 80°CHigh Limit ThermostatFactory-set at 110°C (manual reset)Casing FinishStove enamel painted whiteThermal InsulationBoiler shell and casings insulated with glass fibreOptional Extras <strong>Trian<strong>co</strong></strong> balanced flue kit range (page 19)ModelInputOutput(non <strong>co</strong>ndensing)Output(<strong>co</strong>ndensing)NozzlePumpPressure50,000 52,247 BTUs 50,000 BTUs 50,784 BTUs 0.45 x 80ºEH 120 psi 11.860,000 62,781 BTUs 60,051 BTUs 61,075 BTUs 0.60 x 80ºEH 95 psi 11.570,000 74,723 BTUs 70,970 BTUs 72,676 BTUs 0.60 x 80ºEH 135 psi 11.4CO 2(%)9


4. INSTALLATIONREGULATIONSInstallation of the boiler must <strong>co</strong>mply with the following BritishStandards and Regulations:BS 5410: Part 1 – Code of Practise for <strong>Oil</strong>-Firing.BS 5449 – Forced Circulation Hot Water Central HeatingSystems.Building Regulations- Part J (England and Wales)- Part F sect. 111 (S<strong>co</strong>tland)- Part LThe Control of Pollution (<strong>Oil</strong>) RegulationsCurrent I.E.E. RegulationsLocal Water Undertakings BylawsOFTEC Installation Requirements for <strong>Oil</strong>-Fired <strong>Boilers</strong> and <strong>Oil</strong>Storage Tanks, OFST 100 & OFST 200.<strong>HE</strong>ALTH AND SAFETY AT WORK ACTThe installer should be aware of his responsibilities under theAct and provide, where necessary, appropriate protection forall persons carrying out the installation. In the interests ofsafety, it is required that the appliance is installed,<strong>co</strong>mmissioned and serviced by and OFTEC registeredtechnician. A guide to safe working practices for oil-firingtechnicians is available from OFTEC.LIFTINGThe appliance will require two people to lift into position, orspecialised lifting equipment. Do not mount the boiler on thewall unless all necessary precautions have been made.Electrical work should be carried out in ac<strong>co</strong>rdance with BS7671:2001 by a qualified electrical engineer.Clearance and Service AccessWhen siting the boiler, ensure adequate clearance is allowedfor making water and flue <strong>co</strong>nnections. Routine servicing canbe carried out from the front. See page 8 for clearancedimensions.SYSTEM DESIGNTo achieve the maximum system efficiencies, the heatingsystem should be designed to the following parameters:Boiler Flow Temperature - 50°C to 80°CFlow Differential Temperature - 20°C to 30°C<strong>HE</strong>ATING AND DOMESTIC HOT WATER SYSTEMSThe heating system should be installed in ac<strong>co</strong>rdance withcurrent HVCA Codes of Practice and BS 5449 Part 1 – ForcedCirculation Hot Water Central Heating Systems.Maximum water temperature is 80°C.The flow and return <strong>co</strong>nnections are made via 22mm<strong>co</strong>mpression fittings at the top-right of the boiler, and can berun through either the rear or the top.Where the boiler is also used for providing domestic hot water,a double-feed indirect cylinder to BS 1566 Part 1 must beused.A drain-off <strong>co</strong>ck is fitted to the underside of the boiler.However, one should always be fitted to the lowest point on theheating circuit.Flush out the system to remove any residue before filling thesystem.SITING T<strong>HE</strong> BOILERSound LevelsDespite the low sound levels of the boiler, the following factorsshould be taken into <strong>co</strong>nsideration before installation:(a) Some people are particularly sensitive to low noise levels– discuss with the householder.(b) Small rooms tend to amplify noise, particularly if the wall<strong>co</strong>nstruction is hollow or the surface tiled.(c) A chimney passing through a bedroom will sometimestransmit noise.(d) Low-level flue terminals produce some exhaust noise, socare should be taken when siting adjacent to neighbouringproperty, patios and play areas. Refer to flue details (page18 onwards).(e) Due to the <strong>co</strong>ndensing nature of the boiler, a plume ofwater vapour will be discharged from the flue. This shouldbe taken into ac<strong>co</strong>unt when siting the flue terminal. Referto section on flue systems.10


CONDENSATE DRAIN CONNECTIONSThe <strong>co</strong>ndensate pipe can be fitted after the boiler is positionedand terminates from the base of the boiler casings.Where possible, <strong>co</strong>nnect the <strong>co</strong>ndensate pipework to anexternal waste drain.If the boiler is to be fitted in a position where the externalground level is higher than the boiler, and there are no internaldrains, a <strong>co</strong>ndensate pump can be fitted (refer tomanufacturers' instructions).The drain pipe must be installed to allow the <strong>co</strong>ndensate todrain naturally from the boiler, on a minimum fall of 1:20.IMPORTANT NOTES:When running any external pipework from the trap to the drain,it is essential that the pipework is kept to a minimum and isinsulated to prevent the <strong>co</strong>ndense from freezing.MAINTENANCEThe trap should be inspected at regular intervals to ensure<strong>co</strong>rrect operation, and should be checked as part of the annualservice schedule.The drain from the boiler must be 22mm diameter pipework.The pipework from the <strong>co</strong>ndensate trap to the externaldrain is not supplied with the boiler.Upon successful installation of the <strong>co</strong>ndensate pipework, fillthe trap via the fill point on the <strong>co</strong>ndensate unit, pouring asmall amount of water within, until retained within the 'U'section.Examine the <strong>co</strong>ndensate pipework for any resultant leaks andrectify ac<strong>co</strong>rdingly.Failure to fill the trap with water before firing the boiler mayresult in damage to the drainage pipework and potentially allowthe escape of flue gases. Any damage caused as a result ofnot filling the trap will not be <strong>co</strong>vered by the applianceguarantee.FIG 11 – CONDENSATE PIPEWORKFIG 1211


5. OIL SUPPLYOILThe burner is factory-set to burn 28 sec. Kerosene Class C2 toBS 2869.<strong>Trian<strong>co</strong></strong> makes no guarantee as to the satisfactory operation ofthe boiler using fuels other than that which is stated above.STORAGE TANKThe tank should be fitted with weather-protected fill and vent<strong>co</strong>nnections, a drain-off <strong>co</strong>ck, and an oil level indicator.Size and Location of TankThe tank should be large enough to allow for e<strong>co</strong>nomicdeliveries and be located in an unobtrusive position, havingregard to the need for safety, filling, maintenance, and head ofoil required (see figs 13, 14, 15).Steel TanksSteel tanks must <strong>co</strong>mply with the requirements of BS 799 Part5: 1987 and should be mounted on brick or block piers, with awaterproof membrane fitted between the piers and tank.Plastic TanksPolyethylene tanks may be used, having several advantagesover traditional steel tanks:(a) Pier supports are not required; the tank may be fitteddirectly onto a flat surface.(b) They do not <strong>co</strong>rrode; therefore never require repainting.(c) They are easier to handle because of lower weight.(d) They are generally supplied with a 10-year manufacturer’sguarantee.Fire ProtectionWhilst it is highly unlikely that a fire <strong>co</strong>uld start from a domesti<strong>co</strong>il tank, protection is required from a fire which may originateelsewhere. The tank should be at least 1.8 metres from abuilding and 750mm from a site boundary. Where it is notfeasible to adhere to these limits, the building wall must nothave any openings other than those for ventilation, the wallmust have at least a half-hour resistance to fire, and mustextend 1.8 metres from any part of the tank.Alternatively, a non-<strong>co</strong>mbustible radiation barrier can beemployed, which meets all the requirements of BS 5410 Part 1.This standard applies to tanks up to a capacity of 3,500 litres.See current OFTEC regulations for further details.To <strong>co</strong>mply with OFTEC regulations, a CD/10 form mustbe <strong>co</strong>mpleted and left with the appliance uponinstallation.To <strong>co</strong>mply with Building Regulations, section J5:1. Where the tank is close to a dwelling, fire protection mustbe provided to the eaves, if less than 1.8 metres from thetop of the tank.2. Cladding must extend at least 300mm beyond the tank.3. The tank must be fitted on a non-<strong>co</strong>mbustible base.Pollution ProtectionTo <strong>co</strong>mply with Building Regulations, section J6, the tankmust be bunded (double-walled) if:1. The tank is less than 10m from a stream2. The tank is less than 50m from a well, spring, or othersource of drinking water.3. The tank cannot be viewed from the point of delivery.4. There is risk of oil reaching a manhole <strong>co</strong>ver or drain inthe event of a leak.5. The tank capacity exceeds 2,500 litres.SUPPLYA long-life flexible oil hose is supplied with the boiler. A filterand shut-off valve are also required. These should be fitted asshown on figs 13, 14, 15.All oil line joints must be <strong>co</strong>mpletely sealed and the total piperun should be flushed thoroughly before <strong>co</strong>nnection is made tothe burner. No soldered joints are permitted in the oil line.Fire ValveA remote-operated fire valve must be fitted in the oil supplyline, externally to the boiler, with the sensing phial located at apoint within the boiler casings, above the burner.Single-Pipe <strong>Oil</strong> Supply (fig 14)Where the lowermost part of the tank is above the level of theburner, a single-pipe gravity system can be used. The oilsupply pipe should be <strong>co</strong>nnected to the suction port on theburner pump via the flexible hose supplied.When using the single-pipe system, it is important to <strong>co</strong>nvertthe fuel pump on the burner to operate as such: remove theend <strong>co</strong>ver and filter, then remove the bottom screw and inserta ‘U’-shaped washer. Replace the screw, making sure it is fullyinserted. See the burner details leaflet for further information.Two-Pipe <strong>Oil</strong> Supply (fig 15)Where the lowermost part of the tank is below the level of theburner, a two-pipe suction lift is necessary.A spring-loaded non-return valve must be fitted in the suctionline to prevent the oil running back to the tank. No valves arepermitted in the return line. An additional flexible oil line willalso be required.12The oil pump is factory-set for use with a two-pipe system.


OIL SUPPLY (<strong>co</strong>nt.)Notes:1. The pump suction should not exceed 0.4bar, as dissolvedgas may be released from the oil, affecting <strong>co</strong>mbustion.2. The return pipe must end at the same level as the suctionoutlet to prevent loss of prime.3. The outlet from the tank should be approximately 75mm(3”) above the bottom to prevent sediment and waterbeing drawn into the supply line.Single-Pipe <strong>Oil</strong> Supply with De-aerator (fig 13)Where a two-pipe suction lift is required, but the return piperequirement is too long, or impractical to run, an oil de-aeratorcan be used. The burner should be piped as for a two-pipesystem, up until the de-aerator, when a single pipe can betaken the remaining distance to the storage tank. The deaeratorshould be fitted at the closest point to the boiler,externally to the dwelling.A non-return valve is not required with this system. The pumpis supplied ready for fitting to an oil de-aeration device.FIG 13INSTALLATION WITH OIL DE-AERATOR13


FIG 14SINGLE-PIPE SUPPLY14


FIG 15TWO-PIPE SUPPLY15


6. ELECTRICAL SUPPLY230V single-phase 50Hz (fused 5 amp)Note:this appliance must be earthed and the electricalsupply cable must be of a greater length than thecurrent-carrying <strong>co</strong>nductor cables (i.e. live and neutralsupply cables).All electrical wiring must be carried out by a qualifiedelectrician, in ac<strong>co</strong>rdance with current I.E.E. Regulations andany local regulations which may apply.High and Low Voltage WarningIn certain areas of the <strong>co</strong>untry, where there is a known risk ofhigh or low voltage fluctuations, the burner should beprevented from starting by the use of a voltage-sensitivedevice if the voltage drops or increases sufficiently to endangerthe installation.The 230V – 50Hz electrical supply must be fused by a doublepoleswitch, with a <strong>co</strong>ntact separation of at least 3mm in bothpoles, and by a shuttered socket adjacent to the boiler (bothdevices must meet the requirements of BS 1363).The minimum requirement for the power supply cable is PVCsheathed flexible <strong>co</strong>rd, 0.75mm² (24x0.2mm, <strong>co</strong>de designationH05 VV-F or H05 VVH2-F), as specified in table 16 of BD6500.All cables entering the <strong>co</strong>ntrol box must be secured in positionby the use of strain-relief bushes (supplied, see fig 16 for fittinginstructions).See wiring diagram, fig 17 for further details.Important Note:After wiring in the electrical supply, care must be takenwhen attaching the <strong>co</strong>ntrol box to ensure no cables aretrapped between the boiler and the box.FIG 16FIG 17WIRING DIAGRAMMains Supply 230V 1PH 50HzD/P Switch to suit L.AFused 5 amp16


7. MOUNTINGThe boiler should be fixed to a suitable load-bearing wall usingthe fasteners supplied. If these are not appropriate, otherfasteners may be used provided they are equally as strong.Remove the front door and outer casing assembly from theboiler, moving to a place where they will not invite damage. Forease of lifting, it may be useful at this stage to remove thebaffles and burner. Ensure all baffles are replaced in the ordershown on page 31.Using the template supplied, work out the intended position ofthe boiler and fix the template to the wall. Drill 6mm holeswhere indicated and if using a horizontal balanced flue, cut ahole 130mm diameter in the wall.Remove the wall template and fix the two mounting bracketsprovided to the wall where indicated.Hang the boiler onto the lugs on the large mounting bracketand drill through one holes in the oil pipe bracket. Fit a plasticwall plug and screw back to the wall.Fit the casing over the boiler, locating the back top return of thecasing over the smaller of the two mounting brackets on thewall. Mark through the holes in the bottom rear of the casingand drill through into the wall. Insert a wall plug and screw thecasing back to the wall.Fit the door casing.CAUTION: Uneven LoadFIG 18 – WALLMOUNTING TEMPLATESee fig 3 for flue sideexit dimensions17


8. FLUES AND VENTILATIONVENTILATIONAs the <strong>Contractor</strong> WM70 <strong>HE</strong> is a balanced-flue appliance, theprovision of an adequate supply of <strong>co</strong>mbustion air is notnecessary. However, adequate ventilation is required for the<strong>co</strong>oling of the boiler <strong>co</strong>ntrols if the appliance is to be installed ina <strong>co</strong>mpartment or <strong>co</strong>nfined space (see fig 19).The air opening should be positioned so as to cause the leastpossible draught to the occupants and located so it is not liableto be accidentally blocked.British Code of Practice BS 5410: Part 1 requires a permanentair inlet opening of 550mm 2 per kW of boiler rated outputabove 5kW.The following air openings, shown on fig 19, are required forthe <strong>Contractor</strong> WM70 <strong>HE</strong>.Output Detail ‘A’ (fig 19)50,000 Btu/h 53cm²60,000 Btu/h 69cm²70,000 Btu/h 83cm²FIG 19VENTILATION18


BALANCED FLUE SYSTEMSThe <strong>Trian<strong>co</strong></strong> balanced flue system offers much greaterflexibility for siting the boiler <strong>co</strong>mpared with a <strong>co</strong>nventionalchimney. The only requirement is for a suitable outsidesurface, through which to fit the terminal.In addition to the siting benefit, the performance of balancedflue boilers is virtually unaffected by high wind <strong>co</strong>nditions asthe wind pressures are applied equally to both the air intakeand discharge points, thus creating a balanced <strong>co</strong>ndition.Whereas some balanced flue boilers rely on case sealing toachieve a room seal, the <strong>Contractor</strong> WM70 <strong>HE</strong> has a sealedair duct system which maintains room sealed performanceeven when the casing is removed for burner <strong>co</strong>mmissioningand service.The use of the balanced flue principle also enhances theoverall thermal efficiency of the boiler, as the in<strong>co</strong>ming airextracts waste heat from the flue and returns it as preheatedair to the burner to aid <strong>co</strong>mbustion.Balanced-flue <strong>co</strong>ndensing boilers are designed to operate atlow noise levels.INSTALLATION NOTES1. At certain times during operation, a plume of<strong>co</strong>ndensation will be produced from the terminal. Whenpositioning, this should be taken into <strong>co</strong>nsideration toensure a nuisance is not caused to neighbouringproperties.2. The flue terminal should not be positioned where theproducts of <strong>co</strong>mbustion <strong>co</strong>uld enter the building (refer tofig 20 for guidance).3. Keep the terminal clear of infra-red sensing devicessuch as those used to <strong>co</strong>ntrol security lighting.4. Positioning of the terminal below a bal<strong>co</strong>ny or carportshould be avoided.5. As the system operates under positive pressure, it isessential that all flue joints are sealed <strong>co</strong>rrectly.6. Only 28. se<strong>co</strong>nd kerosene class C2 to BS 2869 hasbeen tested for use with this appliance.Note:<strong>Trian<strong>co</strong></strong> balanced flue kits have been designed andtested exclusively for use with <strong>Trian<strong>co</strong></strong> boilers. Assuch, <strong>co</strong>mpatibility with other makes of boilercannot be guaranteed.FIG 20 – TERMINAL POSITIONS19


Horizontal Balanced Flue Kits 2358 & 2359Before <strong>co</strong>mmencing assembly, please make sure that you have <strong>co</strong>rrectly identified the placement of each pipe section andthat all ‘O’ ring seals are in position and well-lubricated.Assembly Method (figs 21 to 22)1. Having decided the position of the boiler, accurately markout the position of the terminal and cut a circular hole130mm in diameter through the wall.2. Secure the air box (item 1) and underside gasket (3) tothe top of the boiler using the nuts provided. Feed theelbow (4) through the opening on the air box and fit to thespigot in the top of the boiler, ensuring the open end isdirected towards the cutout in the wall.3. Fit the remaining two gaskets (3) and <strong>co</strong>ver (2) to the airbox, ensuring an air tight seal is made.4. Ensuring the 'O'-ring seal (8) is in position and welllubricated,slide the flue mid-section (5) through the walland locate over the inner elbow and outer <strong>co</strong>nnection onthe air box. Secure in position using the clamping strap (7)provided.5. Slide the terminal (6) through the wall and locate in theflue mid-section. Adjust the terminal length as required,making sure a minimum distance of 140mm is kept fromthe end of the terminal from the external face of the wall.Alternatively, fit the flue terminal to the mid-section beforelocating through the wall.6. Connect the hose from the burner to the socket on theinternal air chute using the jubilee clip provided.7. Seal around terminal on the inside and outside wall withan appropriate material.Important Notes:(a) To aid assembly, it will be necessary to apply a thin beadof lubricant to all flue joints which in<strong>co</strong>rporate ‘O’-rings.(b) As the flue system operates under positive pressure, allflue joints must be well sealed. All joints which do notin<strong>co</strong>rporate ‘O’-rings must be sealed with sili<strong>co</strong>ne sealant.(c) As the boiler produces <strong>co</strong>ndensate during normal running,it is important that all seals are made and the <strong>co</strong>rrectgaskets used.(d) To ensure that any <strong>co</strong>ndensate produced in the flue drainsaway, incline the flue slightly upwards from the boiler.EXTENDING T<strong>HE</strong> FLUEShould the horizontal length of the standard flues not meetyour requirements, additional sections of flue pipe can bepurchased to extend the maximum wall thickness limit. 45º and90º elbows can be purchased in order to offset the flue aroundobstructions. See page 29 for details.TERMINAL GUARDWhere the terminal is positioned in a place where there is thepossibility of <strong>co</strong>ntact being made by persons, or of damage tothe terminal, an approved terminal guard is necessary.Generally, exhaust 2 metres above ground level alleviates therequirement for a terminal guard.A suitable stainless steel terminal guard is available from<strong>Trian<strong>co</strong></strong> (part <strong>co</strong>de 223920).FIG 212358 & 2359 HORIZONTAL BALANCEDFLUE KITS20


FIG 222358 & 2359 HORIZONTAL BALANCED FLUE KIT DETAILSHOLE REQUIRED 130mm DIAMETERTHROUGH WALL TO TAKE TERMINALIMPORTANT:W<strong>HE</strong>N INSTALLING T<strong>HE</strong> FLUE SYSTEM, IT ISESSENTIAL THAT T<strong>HE</strong> FLUE INCLINES SLIGHTLYFROM T<strong>HE</strong> BOILER. THIS WILL ALLOWANY CONDENSATION WHICH FORMS IN T<strong>HE</strong> FLUE TORUN BACK TO T<strong>HE</strong> CONDENSATE DRAIN21


22FIG 23 - 2355 & 2356 Horizontal Balanced Flue(to be used in <strong>co</strong>njunction with 2357 High Level Adaptor Kit only)


FIG 242357 – High Level Adaptor Kit(used in <strong>co</strong>njunction with 2355 or 2356Horizontal High Level Balanced Flue Kits only)23


24FIG 252357 – HIGH LEVEL ADAPTOR KIT(USED IN CONJUNCTION WITH 2355 AND 2356 FLUE KITS ONLY)


High-Level Balanced Flue Kit (2357)Before <strong>co</strong>mmencing assembly, please make sure that you have <strong>co</strong>rrectly identified the placement of each pipe section andthat all ‘O’ ring seals are in position and well-lubricated. Any white pipe exposed to the elements should be protected with asuitable material. Place all weld seams to the rear.ASSEMBLY METHODBefore assembly, determine the length of flue required and ifnecessary discard the mid-section. See "alternative verticallengths" (adjacent) for details of different flue lengths.1. Having decided the position of the boiler, cut a hole130mm diameter in the wall. Refer to fig 25 and"alternative flue heights" for high level flue positions.2. Ensuring the 'O'-ring seal (3) is in position and welllubricated,fit the flue mid-section (4) into the spigotattached to the boiler, pushing the outer sections of pipefirmly together. Use the clamping strap (2) to fasten theseitems securely to create a seal.3. Fit the lower flue section (item 4) to the spigot (item 6),now situated on top of the boiler, ensuring the 'O'-ringcreates a good seal.4. Ensuring that all 'O'-ring seals are in position and welllubricated,fit the elbow (item 1, fig 23) from the horizontalbalanced flue kit to the top of the flue mid-section, pushingfirmly together until the outer sections meet. Use theclamping strap to fasten these items securely together.5. Decide the length of horizontal run required and slide theterminal (item 4, fig 23) into the horizontal mid-section(item 2, fig 23). Once in the required position (andensuring that at least 140mm will project from the outsidewall), seal these items together using a suitable material.6. Ensuring that all 'O'-rings are in position, slide the<strong>co</strong>mpleted terminal assembly through the wall and fit tothe flue elbow, pushing firmly together until the outersections meet. Use the remaining clamping strap to fastenthese items securely together.7. Use the clip provided to secure the air hose from theburner to the <strong>co</strong>nnection on the air box assembly insidethe boiler.8. Perform a final check of the flue. Ensure all clampingstraps are located over all relevant flue joints.9. Seal any remaining gaps in the wall around the horizontalflue section with a suitable material.ALTERNATIVE FLUE <strong>HE</strong>IGHTSShould the height of the flue (see fig 25) not meet yourrequirements, alternative arrangements can be made bypurchasing additional sections of flue pipe to extend thevertical distance. See page 29 for details.ALTERNATIVE HORIZONTAL LENGTHSShould the horizontal length of the standard flues not meetyour requirements, an additional section of flue pipe can bepurchased to extend the maximum wall thickness limit. Seepage 29 for details.ADDITIONAL ELBOWSWhen used in <strong>co</strong>njunction with additional horizontal lengthsof flue, 45º and 90º elbows can be purchased in order tooffset the flue on the horizontal plane. See page 29 fordetails.Additional 45º elbows can be purchased to offset the verticalsections of flue. 90º elbows cannot be used on the verticalsections. See page 29 for details.IMPORTANT:The total flue distance, vertical and horizontal, must notexceed 6000mm. Any 45º elbows used in the assembly<strong>co</strong>ntribute 500mm to the calculation. 90º elbows <strong>co</strong>ntribute1000mm to the calculation.To ensure that any <strong>co</strong>ndensate produced in the flue drainsaway <strong>co</strong>rrectly, incline the flue slightly upwards from theboiler.TERMINAL GUARDWhere the terminal is positioned in a place where there isthe possibility of <strong>co</strong>ntact being made by persons, of damageto the terminal, or if it is lower than 2 metres from groundlevel, an approved terminal guard is necessary.Generally, exhaust 2 metres above ground level willalleviate the requirement for a terminal guard.A suitable stainless steel terminal guard is available from<strong>Trian<strong>co</strong></strong> (part <strong>co</strong>de 223920).25


Vertical Balanced Flue Kit (2360)Before <strong>co</strong>mmencing assembly, please make sure that you have <strong>co</strong>rrectly identified the placement of each pipe section andthat all ‘O’ ring seals are in position and well-lubricated. Any white pipe exposed to the elements should be protected witha suitable material. Place all weld seams to the rear.ASSEMBLY METHODThe flue can either be assembled on the ground before attaching tothe boiler, or piece-by-piece in situ. If the former, ensure that allclamping straps (items 11 & 12, fig 26) are loosely in position overthe flue joints. If the latter, ensure that none of the flue joints aresituated within the joist space.The total flue length required should be determined beforeassembly. If necessary, discard the mid-sections (item 7), as theiruse is not essential. See fig 27 for details of different flue lengths.1. Secure the boiler in position and cut a hole 175mm diameter inthe ceiling and roof. Ensure the flue will have a minimumclearance of 25mm from any <strong>co</strong>mbustible material.2. Ensure all 'O'-ring seals (item 5) are in position on all sectionsof pipe. Apply a thin bead of lubricant around each 'O'-ring.3. Fit the first flue mid-section (item 7) to the spigot situated ontop of the boiler, ensuring the 'O'-ring creates a good seal andpushing firmly down until the outer sections meet. Use theclamping strap (item 11) to fasten these items securelytogether. Fit the se<strong>co</strong>nd flue mid-section (also item 7), and thethird flue section (item 8) to the previous sections in the samemanner.Note: both instances of item 7 can be discarded if they are notrequired. Of the main flue sections, only the use of items 8 ismandatory. Fit these together in the manner described above.4. The first terminal section (item 9) fits over the precedingsection of flue without the use of the clamping strap, and inorder to achieve a more accurate fit distance is teles<strong>co</strong>picin nature. Once the length has been set, drill through theouter pipe and secure with self-tapping screws.5. If necessary, fit the terminal (item 10) to the terminal lowersection before it is attached to the last main flue section.Push firmly down until the outer sections meet and use thestainless steel clamping strap (item 12) to fasten thesesecurely together.6. Fit the ceiling plates (item 13) centrally over the inner hole,ensuring the outer flue pipe has a minimum clearance of25mm from any <strong>co</strong>mbustible material. Pack the space withglass fibre insulation.7. Secure the flue to the roof space and fit waterproof flashing(not supplied) around the flue at the roof line.8. Use the clip provided to secure the air hose from the burnerto the <strong>co</strong>nnection on the air box assembly inside the boilerADDITIONAL FLUE <strong>HE</strong>IGHTS & ELBOWSShould the maximum height of the flue not meet yourrequirements, additional sections of flue pipe can bepurchased to extend the vertical distance. See page 29fordetails.45º elbows can be purchased to offset the flue to keep clear ofany permanent obstructions. See page 29 for details. 90ºelbows cannot be used with this flue.IMPORTANT: The total flue distance, vertical and horizontal,must not exceed 6000mm. Any 45º elbows used in theassembly <strong>co</strong>ntribute 500mm to the calculation.26


FIG 26VERTICAL BALANCED FLUE KIT (2360)27


Note 'X' – Shorter flue distances can be achieved bydiscarding these sections. Longer flue distances canbe achieved by purchasing additional sections ofpipe (see page 29).Permanent obstructions may be avoided by the useof 45º elbows (see page 29).FIG 27VERTICAL BALANCED FLUE KIT (2360)28


Optional ExtrasCombinations of the following items can be purchased in order to provide alternative flue <strong>co</strong>nfigurations:2361 – Long Flue Extension 2363 – 45º Elbow2362 – Short Flue Extension 2364 – 90º Elbow2361 – Long Flue Extension2362 – Short Flue ExtensionThese flue extensions can be used to extend the vertical lengthof the flue, or the horizontal length, in almost any <strong>co</strong>mbination of<strong>co</strong>nfigurations.The total flue distance, vertical and horizontal, must not exceed6000mm. Any 45º elbows used in the assembly <strong>co</strong>ntribute500mm to the calculation. 45º elbows can be used to offset thevertical sections of flue on both the high level and vertical fluekits. Ensuring all 'O'-ring seals are in position and well-lubricated,push the elbow and flue pipe firmly together, fixing together withthe clamping strap provided.2363 – 45º ElbowExample:2 x 45º elbows used to offsetvertical flue extensions.Note: only 45º elbows can beused on vertical sections offlue. 90º elbows must only beused to offset the high-levelflue on the horizontal plane.2364 – 90º ElbowFIG 28Any 90º elbows used in the assembly <strong>co</strong>ntribute 1000mm to theabove calculation. 90º elbows can only be used on the highlevel adaptor kits to offset the flue on the horizontal plane.Ensuring all 'O'-ring seals are in position and well-lubricated,push the elbow and flue pipe firmly together, fixing together withthe clamping strap provided.29


9. COMMISSIONINGThe burner must be <strong>co</strong>mmissioned by a qualified OFTECregisteredtechnician, and a CD/10 form <strong>co</strong>mpleted.It is the responsibility of the installer to ensure the boiler is<strong>co</strong>rrectly <strong>co</strong>mmissioned. Failure to do so will make the boiler'sguarantee and any extended warranty null and void.Although all burners are factory-tested before despatch, due toindividual site <strong>co</strong>nditions they will usually require furtheradjustment after installation to achieve the readings specifiedin the burner details leaflet.PROCEDURE1. Switch off electrical and oil supply and ensure boiler is fullof water. Ensure all isolation valves are open.2. Check that all baffles are <strong>co</strong>rrectly positioned (fig 29).3. Dis<strong>co</strong>nnect oil line(s) from burner. Run off a small quantityof oil. Check for a clean, air-free supply and re<strong>co</strong>nnect.4. Check system <strong>co</strong>ntrols are in the ON position. Ensureboiler stat and any room stats are calling for heat. Switchon the electrical supply; the burner should now start.Note: the burner may lock-out upon first firing due to air in thepump. Should this occur, wait for one minute before pressingthe burner reset button. Should lock-outs persist, the air can bedriven out of the oil supply via the pressure gauge <strong>co</strong>nnectionon the pump.5. Start and stop the burner several times until the burnercuts out sharply; this will indicate that any remaining airhas been expelled from the oil supply.6. Allow to burner to run for fifteen minutes before using aflue gas analyser to take a CO 2 reading from either thesampling point on the baffle access <strong>co</strong>ver, or the terminal.Compare with the readings specified in the burner detailsleaflet and adjust the air setting as necessary. Ensure theflue gases are smoke-free.7. If the system is not to be put into immediate operation,isolate the electrical and oil supplies. If there is apossibility of the water in the system freezing, this shouldbe drained.HANDING OVERAfter satisfactorily <strong>co</strong>mpleting the boiler installation and<strong>co</strong>mmissioning, a thorough check of the system should bemade, and the use of any boiler and system <strong>co</strong>ntrolsdemonstrated to the end-user. All instructions should be lefton-site and advice given as to the need for an annual service.10. SERVICINGIMPORTANT: ISOLATE T<strong>HE</strong> ELECTRICAL SUPPLY TO T<strong>HE</strong>BOILER BEFORE SERVICING.Before carrying out the service, please read the health andsafety information given at the start of this manual.To maintain the boiler's high thermal efficiency and ensurereliable operation, the appliance should be serviced annuallyby a qualified OFTEC-registered technician. Electrical workshould be carried out by a qualified engineer. A CD/11servicing and <strong>co</strong>mmissioning form should be <strong>co</strong>mpleted andleft with the appliance on-site.If the boiler is in use all year round, the best time for theservice is before the start of the heating season. Where theboiler is shut down for the summer months, the service shouldbe carried out as soon as is possible after the end of theheating season.OIL TANKOpen the tank drain-off and allow any accumulated water andsludge to drain away.LINE FILTERSTurn off the oil supply and remove the filter bowl. Wash thefilter clean with kerosene.The following checks should also be carried out:1. Ensure the air inlets on the flue terminal are not obstructedor blocked.2. Ensure all external <strong>co</strong>ntrols are working <strong>co</strong>rrectly.3. Ensure all ventilation openings are not obstructed, and areof an adequate size.4. Inspect all boiler <strong>co</strong>nnections for soundness.5. Inspect the flexible oil line(s), and replace wherenecessary.CONDENSATE PIPEWORK & TRAPThe <strong>co</strong>ndensate pipework and trap should be inspected as partof the annual service schedule.Ensure there are no blockages within the <strong>co</strong>ndensate pipeworkand the ‘U’ trap.When <strong>co</strong>mplete, recheck the integrity of the pipework joints bypouring a small amount of water into the fill point on the<strong>co</strong>ndensate unit.Failure to ensure the retention of water will result in thein<strong>co</strong>rrect operation of the boiler and potentially damage the<strong>co</strong>ndensate pipework.30


SERVICE PROCEDURE1. Switch off the electrical supply to the boiler and removethe front casing.2. Switch off the oil supply to the burner.3. Remove the flexible air supply hose from the burner.4. Remove the burner. Ensure that if the oil supply line has tobe dis<strong>co</strong>nnected there is no spillage of oil. A peg isprovided on the front of the unit to hang the burner duringservice.5. Remove the baffle access <strong>co</strong>ver from the front of the boilerand lift out the baffles.6. Brush all deposits from the baffles and clean the internalsurfaces of the boiler.7. Remove deposits from the floor of the <strong>co</strong>mbustionchamber with a vacuum cleaner.8. Check the integrity of the access <strong>co</strong>ver seal. Replace asnecessary.9. Remove the access <strong>co</strong>ver from the top of the <strong>co</strong>ndensateunit and clean all accumulated deposits from within.11. Clean any deposits from the blast tube and replace thenozzle.12. Using the diagram below, replace the flue baffles in the<strong>co</strong>rrect arrangement. Failure to ensure the <strong>co</strong>rrectplacement of baffles will result in in<strong>co</strong>rrect <strong>co</strong>mbustion,reducing the efficiency of the boiler and invalidating theappliance warranty.13. Refit the baffle access and <strong>co</strong>ndensate unit <strong>co</strong>vers, ensuringgas-tight seals are made using the wing-nuts and washersprovided.14. Refit the burner and secure the air supply hose back inposition. If removed, refit the oil supply line. Replace the topcasing.15. Switch on the electrical and oil supplies to the appliance.Ensure that the external <strong>co</strong>ntrols are calling for heat. Theboiler should now fire.16. Check the <strong>co</strong>mbustion settings given against those in theburner details leaflet and make any adjustments wherenecessary.17. Check all water <strong>co</strong>nnections and inspect for leaks.10. Check the integrity of the flue and burner gaskets.Replace as necessary.FIG 29BAFFLE CONFIGURATIONBURNER SERVICING PEG(hang burner on peg withblast tube pointed upwards)IMPORTANT:When refitting baffles, failure to ensure the <strong>co</strong>rrect placement will result in in<strong>co</strong>rrect<strong>co</strong>mbustion, reducing the efficiency of the boiler and invalidating the appliance warranty.31


11. SPARESItem Description Part No. Qty1 Boiler Body 224041 12 Main Panel Assembly 224401 13 Front Door 224410 14 Condensing Unit 224060 15 Boiler Control Thermostat 206896 16 High-Limit Thermostat 206892 17 Control Box Assembly 208400 18 Flue Socket Plate 223135 19 Flue Sealing Gasket 223071 110 Flue Gasket 223787 111 Top Baffle 1 224047 212 Middle Baffle Top 1 224020 113 Middle Baffle Bottom 1 224027 214 Bottom Baffle 1 224025 115 Baffle Access Cover 208331 116 Burner 2 224390 117 Flexible <strong>Oil</strong> Line 2 207019 218 A<strong>co</strong>ustic Hose 208388 119 Burner Mounting Flange 224392 120 Burner Mounting Gasket 224391 121 Condensate Pipework 224388 122 Return Pipework Assembly 224389 123 Drain Cock 99592 124 Condensate Unit Access Cover 223898 125 Condensate Unit Access Cover Gasket 223899 126 Flue Gasket (Red) 223787 127 Flue Spigot 223969 128 Flue Gasket 223071 129 Air Box Blanking Gasket 224072 130 Air Box Spigot 224436 131 Air Box 224430 132 <strong>Wall</strong> Mounting Template 224385 133 Automatic Air Vent 207296 11Not shown; see fig 29 (page 31) for baffle <strong>co</strong>nfigurations.2 See burner details leaflet for burner spares.32


12. FAULT-FINDINGBURNER FAULT-FINDINGELECTRICAL SAFETY - before making any electrical checks, switch off the mains supply to the boilerFAULTPOSSIBLE CAUSEACTIONBURNER WILL NOT STARTControl box locked outHigh limit stat trippedSystem <strong>co</strong>ntrols satisfiedFuse blownMotor or pump seizedPress orange reset button on front ofburner. NB: ONLY TRY TWICEPress red reset button (under <strong>co</strong>ntrolpanel) and check function of boiler statEnsure all <strong>co</strong>ntrols are calling for heatFit new fuse (5A). If problem persists,check for short circuit in wiringCheck for rotation, replace as necessaryBURNER STARTS BUTFLAME NOT ESTABLIS<strong>HE</strong>DNo oil supplyPhotocell not seeing flameAir trapped in pumpSolenoid valve faultyNozzle blockedElectrodes in<strong>co</strong>rrectly setElectrode insulator crackedIgnition transformer or leads faultyLow oil pressureCheck oil level in tank, check oil supply foradequate flowClean photocell, ensure it is fully insertedBleed excess air via tapping on oil pumpCheck <strong>co</strong>il for <strong>co</strong>ntinuity, replace asnecessaryReplace nozzle with one of samespecification (see burner leaflet)Reset gap and position to settings shownin burner leafletReplace as necessaryCheck for spark, check <strong>co</strong>ndition of HTleads, replace as necessaryCheck pump pressure and adjust tosettings shown in burner leafletFLAME ESTABLIS<strong>HE</strong>D BUTBURNER LOCKS OUT AFTERA FEW SECONDS<strong>Oil</strong> <strong>co</strong>ntaminated with water<strong>Oil</strong> filter partially blockedPhotocell faultyLow oil pressureRun off oil at burner until free of water anddrain <strong>co</strong>ndensation from tankWash filter clean with keroseneClean photocell, ensure it is fully inserted,check for damage. Replace as necessaryCheck pump pressure and adjust tosettings shown in burner leaflet33


BURNER FAULT-FINDING (<strong>co</strong>nt.)ELECTRICAL SAFETY - before making any electrical checks, switch off the mains supply to the boilerFAULTMORNING START LOCKOUTPOSSIBLE CAUSEFaulty non-return valve or air leakin two-pipe systemLow voltage to applianceCombustion settings in<strong>co</strong>rrect<strong>Oil</strong> level in tank falling belowburnerACTIONReplace non-return valve, cure leakCheck with local electricity boardCheck <strong>co</strong>mbustion under normal running<strong>co</strong>nditions, check against settings shown inburner leafletRaise tank or fir two-pipe systemDELAYED IGNITION (BURNERPULSATES ON STARTUP)Nozzle partially blockedLow oil pressureFlue blocked or damagedFan slipping on shaftPump <strong>co</strong>upling loose or wornReplace nozzle with one of samespecification (see burner leaflet)Check pump pressure and adjust to settingsshown in burner leafletCheck flue and rectify/replace as necessaryCheck fan and retighten/replace asnecessaryCheck fan and rectify/replace as necessaryBURNER STARTS VIOLENTLYDelayed ignitionReset electrode gap and position to settingsshown in burner leafletCheck electrodes for damage, replace asnecessaryCheck <strong>co</strong>ndition of HT leads, replace asnecessaryBURNER REPEATEDLYATTEMPTS TO FIRE(balanced flue only)Exhaust gas in <strong>co</strong>mbustion airRemove air hose from boiler end of flue,leaving burner end in place. If burner startsnormally, check flue for breakdown of sealsand repair/replace as necessaryIf indeterminate, leaving hose attached,pierce a small hole in air hose and use fluegas analyser to check for carbon dioxide. Ifmore than trace elements present, checkflue for breakdown of seals andrepair/replace as necessaryCOMBUSTION FUMES SMELLBaffle access <strong>co</strong>ver not secureBaffle access <strong>co</strong>ver seal damagedBurner in<strong>co</strong>rrectly fitted, or fixinggasket damagedFlue gasket damaged34Tighten wing nuts, securing door in positionReplace seal as necessaryCheck burner fixing gasket, replace asnecessary. Tighten burner mounting nutsCheck gasket, replace as necessary.Tighten flue mounting nuts


TRIANCO <strong>HE</strong>ATING PRODUCTS LTDThorncliffe, ChapeltownSheffield S35 2PHTel: (0114) 257 2300Fax: (0114) 257 1419www.trian<strong>co</strong>.<strong>co</strong>.<strong>uk</strong>© <strong>Trian<strong>co</strong></strong> Heating Products Ltd. Copyright in this brochure and the drawings or illustrations <strong>co</strong>ntained within are vested in <strong>Trian<strong>co</strong></strong>Heating Products and neither the brochure or any part thereof may be reproduced without prior written <strong>co</strong>nsent.36August 2007 Item No. 224452 Issue No. 1

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